Lead frame, package, light emitting device, and method for producing the same

ABSTRACT

A lead frame includes a first electrode, a second electrode, two hanger leads, and an outer frame, and partially forms a box-shaped package which has a first recess for mounting a light emitting element as combined with a support member that supports the first electrode and the second electrode. At least a portion of lower faces of the electrodes, at least a portion of lower faces of the hanger leads, and at least a portion of a lower face of the planned formation area for the support member are coplanarly formed. Lower face corners of the first electrode and the second electrode are rounded while upper face corners of the first electrode and the second electrode are not rounded, and upper face corners of the hanger leads are rounded while lower face corners of the hanger leads are not rounded.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority under 35 U.S.C. § 119 toJapanese Patent Application No. 2015-157219, filed Aug. 7, 2015,entitled “Lead frame, package, light emitting device, and method forproducing the same”. The contents of Japanese Patent Application No.2015-157219 are incorporated herein by reference in their entirety.

BACKGROUND

The present disclosure relates to lead frames, packages, light emittingdevices, and methods for producing the same.

Up to this time, lead frames having hanger leads, packages using suchlead frames, and light emitting devices having semiconductor lightemitting elements installed in such packages have been known as shown,for example, in Japanese Unexamined Patent Application Publication No.2012-28699 and Japanese Registered Utility Model Publication No.3168024.

Packages are formed by applying resin molding or the like to lead framesmade of multiple sets of electrodes and hanger leads attached to theouter frames. Electrodes are supported by resin support members, and theresin support members are supported by multiple hanger leads attached tothe outer frames of the lead frames at the lateral faces so that thepackages will not be scattered when the electrodes are separated fromthe outer frames. This produces a package assemblage in which aplurality of packages are attached to the outer frames by the hangerleads.

Moreover, individual packages can be detached from the assemblage byseparating the support members from the hanger leads by pushing thepackages out in the direction perpendicular to the outer frame surfacesof the lead frames.

SUMMARY

Lead frames are manufactured by press-punching or etching a metal sheetas described, for example, in Japanese Unexamined Patent ApplicationPublication No. 2012-28699. Press-punching particularly is a highlyefficient method, but the metal sheet surface on the punch side of thepunching machine becomes a “dull face” having rounded edges, while themetal plate surface on the die side becomes a “burred face” having burrsalong the edges.

If the packages are formed so that the burred faces of the lead framesare oriented to face away from the support members and thus are exposed,the burrs generated along the edges of the burred faces of theelectrodes can damage other members or cause floating when mounting thedevices. In order to avoid this, the lead frames are oriented so thatthe edges of their burred faces are covered by the support members.Accordingly, the lead frames are positioned to have their dull facesface away from the support members.

At this point, the hanger leads formed in the lead frames are positionedso that their dull faces also face away from the support members. Thehanger leads are disposed so that their tips bite into the lateral facesof the support members, which will be separated therefrom when thepackages are separated into individual pieces.

Here, a package produced by a comparative method will be explained withreference to FIGS. 11A and 11B. FIG. 11A is a sectional view showing thestructure of a comparative package supported by hanger leads. FIG. 11Bis a sectional view showing the comparative package separated from thehanger leads.

In the comparative package 1001, in order to achieve good mountability,the lead frame 1003 is positioned so that the burred face becomes theupper face and the burrs generated on the electrode 1031 are not exposedat the lower face 1012 which is the mounting face. The support member1002 which supports the electrode 1031 is formed by resin molding. Themembers of the lead frame 1003, such as the electrode 1031 and thehanger leads 1035, are formed by press-punching from the same side usinga comparative punching process. The hanger leads 1035 thus are alsoformed with the burred face up and the dull face down.

Resin molding the support member 1002 results in the tips 1351 of thehanger leads 1035 biting into the outer lateral faces 1021 b and 1021 dof the support member 1002. Since the lower corner 1035 e of the dullface of a hanger lead 1035 is rounded, the resin penetrates the spacebetween the flat upper face of the lower die of the resin mold and thedull or rounded portion. As a result, the lower face 1012 of the package1001, which is composed of the lower face 1031 b of the electrode 1031and the lower face 1021 e of the support member 1002, is formed as aflat face.

By applying a pressing force from the lower face side of the package1001, the tips 1351 of the hanger leads 1035 are detached from thesupport member 1002 to separate the package 1001. This creates recesses1024 at the positions where the hanger leads 1035 were once located onthe outer lateral faces 1021 b and 1021 d of the support member 1002.The resin which had penetrated the dull portions are turned over whenthe hanger leads 1035 are separated as the packages are separated intoindividual pieces to become projecting resin burrs 1027. Such resinburrs 1027 might adversely affect the adhesion of the package 1001 to acircuit board during mounting, reducing the mountability.

Certain embodiments of the present disclosure aim to provide lead frameswhich allow for the production of packages and light emitting deviceswith good mountability, packages, light emitting devices, and the methodfor producing the same.

The lead frame according to one embodiment of the present disclosurecomprises electrodes, hanger leads disposed spaced apart from theelectrodes, and an outer frame attached to the electrodes and the hangerleads, and the lead frame partially defines a box-shaped package, whichhas a first recess for mounting a light emitting element, as combinedwith a support member made of a resin for supporting the electrodes. Thefirst recess has an opening defined by lateral walls formed by thesupport member, and a bottom face at least partially formed by theelectrodes; at least a portion of lower faces of the electrodes, atleast a portion of lower faces of the hanger leads, and at least aportion of a lower face of a planned formation area for the supportmember are coplanarly formed; lower face edges of the electrodes arerounded while upper face edges of the electrodes are not rounded; andupper face edges of the hanger leads are rounded while lower face edgesof the hanger leads are not rounded.

The lead frame according to another embodiment of the present disclosurecomprises electrodes, hanger leads disposed spaced apart from theelectrodes, an outer frame attached to the hanger leads, and a supportmember made of a resin and supporting the electrodes, and the electrodesand the support member form a box-shaped package which has a firstrecess for mounting a light emitting element. The first recess has anopening defined by lateral walls formed by the support member, and abottom face at least partially formed by the electrodes; at least aportion of lower faces of the electrodes, at least a portion of lowerfaces of the hanger leads, and at least a portion of a lower face of thesupport member are coplanarly formed; lower face edges of the electrodesare rounded while upper face edges of the electrodes are not rounded;and upper face edges of the hanger leads are rounded while lower faceedges of the hanger leads are not rounded.

The package according to one embodiment of the present disclosure is abox-shaped package comprising electrodes and a support member made of aresin, supporting the electrodes, and having a first recess for mountinga light emitting element. The first recess has an opening defined bylateral walls formed with the support member, and a bottom face at leastpartially formed with the electrodes; at least a portion of lower facesof the electrodes and at least a portion of a lower face of the supportmember are coplanarly formed; upper face edges and lateral faces of theelectrodes are covered by the support member, and lower face edges ofthe electrodes are rounded while the upper face edges are not rounded;the support member has second recesses on the lateral walls at a side ofthe lower face of the support member; and upper end inner edges of thesecond recesses are rounded.

The light emitting device according to one embodiment of the presentdisclosure has the package described above and a light emitting elementmounted in the first recess discussed above.

The method for producing the lead frame according to the embodiments ofthe present disclosure includes press-punching a metal sheet such that adirection of punching perimeters of electrodes and a direction ofpunching perimeters of hanger leads are opposite one another. The leadframe includes the electrodes, the hanger leads disposed spaced apartfrom the electrodes, and an outer frame attached to the electrodes andthe hanger leads, the lead frame partially defining a box-shapedpackage, which has a first recess for mounting a light emitting element,as combined with a support member made of a resin for supporting theelectrodes, the first recess having an opening defining by lateral wallsformed by the support member and a bottom face at least partially formedby the electrodes.

The method for producing the package according to certain embodiments ofthis disclosure includes forming the lead frame by the method forproducing the lead frame, interposing the lead frame between an upperdie and a lower die of a molding die which is configured to move in anup-down motion and has a cavity for forming the lateral walls, injectinga first resin into the molding die interposing the lead frame, andcuring or solidifying the first resin injected into the molding die.During the interposing of the lead frame, burred faces of the electrodesface the cavity, edges of the electrodes are positioned inside an areawhere the cavity is disposed in a plan view, and tips of the hangerleads are positioned inside the area where the cavity is disposed in theplan view.

The method for producing the light emitting device according to certainembodiments of the present disclosure includes forming theaforementioned package by the method for producing the package describedabove, and mounting the light emitting element in the aforementionedfirst recess of the package.

According to the lead frame, the package, the light emitting device, andthe production methods for the same of the embodiments of the presentdisclosure, packages and light emitting devices having good mountabilitycan be produced.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the invention and many of the attendantadvantages thereof will be readily obtained as the same becomes betterunderstood by reference to the following detailed description whenconsidered in connection with the accompanying drawings, wherein:

FIG. 1 is a perspective view showing the package structure according toEmbodiment 1.

FIG. 2A is a plan view showing the package structure according toEmbodiment 1.

FIG. 2B is a bottom view showing the package structure according toEmbodiment 1.

FIG. 2C is a sectional view showing the package structure according toEmbodiment 1 along line IIC-IIC indicated in FIG. 2A.

FIG. 3 is a flowchart showing the steps of the production method for thepackage according to Embodiment 1.

FIG. 4A is a plan view showing the structure of the lead frame formed inthe first outline forming step of the method for producing the packageof Embodiment 1.

FIG. 4B is a sectional view along line IVB-IVB indicated in FIG. 4Ashowing the first outline forming step in the method for producing thepackage of Embodiment 1.

FIG. 4C is a sectional view along line IVC-IVC indicated in FIG. 4Ashowing the first outline forming step in the method for producing thepackage of Embodiment 1.

FIG. 5A is a plan view showing the structure of the lead frame formed inthe second outline forming step of the method for producing the packageof Embodiment 1.

FIG. 5B is a sectional view along line VB-VB indicated in FIG. 5Ashowing the second outline forming step in the method for producing thepackage of Embodiment 1.

FIG. 6A is a sectional view showing the lead frame positioning step ofthe method for producing the package of Embodiment 1.

FIG. 6B is a plan view showing the lead frame positioning step of themethod for producing the package of Embodiment 1.

FIG. 7A is a sectional view along line VIIA-VIIA indicated in FIG. 6Bshowing the first resin injecting step in the support member formingstep of the method for producing the package of Embodiment 1.

FIG. 7B is a sectional view along line VIIB-VIIB indicated in FIG. 6Bshowing the first resin injecting step in the support member formingstep of the method for producing the package of Embodiment 1.

FIG. 7C is a sectional view along line VIIC-VIIC indicated in FIG. 6Bshowing the first resin injecting step in the support member formingstep of the method for producing the package of Embodiment 1.

FIG. 8 is a plan view showing the electrode separating step of themethod for producing the package of Embodiment 1.

FIG. 9 is a perspective view showing the structure of the light emittingdevice according to Embodiment 1.

FIG. 10 is a flowchart showing the steps of the method for producing thelight emitting device according to Embodiment 1.

FIG. 11A is a sectional view showing the structure of a comparativepackage supported by hanger leads.

FIG. 11B is a sectional view showing the structure of a comparativepackage separated from hanger leads.

DESCRIPTION

The embodiments will now be described with reference to the accompanyingdrawings, wherein like reference numerals designate corresponding oridentical elements throughout the various drawings.

The lead frame, the package, the light emitting device, and the methodsfor producing the same according to certain embodiments will beexplained below. The drawings referenced in the explanation areschematic representation of the embodiments, and thus the scale,spacing, positional relationship of the members may be exaggerated, orthe members may be partially omitted. In the explanation below, themembers referred to by the same names or denoted by the same referencenumerals represent the same members or those of a similar nature as arule, for which the explanations will be omitted when appropriate.

For the sake of convenience, the directions of observation are indicatedby using XYZ coordinate axes.

Embodiment 1

Package Structure

The structure of the package according to Embodiment 1 will be explainedwith reference to FIG. 1 to FIG. 2C.

FIG. 1 is a perspective view showing the package structure according toEmbodiment 1. FIG. 2A is a plan view of the package structure accordingto Embodiment 1, and FIG. 2B is a bottom view of the package accordingto Embodiment 1. FIG. 2C is a sectional view along line IIC-IICindicated in FIG. 2A showing the package structure according toEmbodiment 1.

The package 1 of Embodiment 1 has an overall shape of a parallelepiped,and is box-shaped with a first recess 11 which is open at the top. Here,a box shape refers to a hollow shape, and in this embodiment, thepackage 1 is cup-shaped and is open at the top. In a plan view, theshape of the cup which is open at the top is substantially rectangularwith rounded corners, but it can also be circular, elliptical,polygonal, or the like. The package 1 includes a first electrode 31, asecond electrode 32 having a different polarity from that of the firstelectrode 31, and a support member 2 for supporting the first electrode31 and the second electrode 32.

The first recess 11 is a cavity for mounting a light emitting element 4.The lateral faces of the first recess 11 are surrounded by the walls 22of the support member 2, and the bottom face 11 a is formed by the firstelectrode 31, the second electrode 32, and the support member 2. Inother words, at least some portions of the bottom face 11 a of the firstrecess 11 are composed of the inner lead portion 311 of the firstelectrode 31 and the inner lead portion 321 of the second electrode 32.The first recess 11, moreover, is shaped so as to widen towards the openend, in the +z direction. The lower faces 31 b and 32 b of the firstelectrode 31 and the second electrode 32 are exposed at the lower face12 of the package 1, which form the mounting face for mounting thepackage 1 on a substrate or the like. Moreover, the lower faces 31 b and32 b of the first electrode 31 and the second electrode 32 and the lowerface 21 e which is the lower end face of the support member 2 are formedto be coplanar, i.e., the lower face 12 of the package 1 is formed to beflat.

In each drawing, the coordinate axes are set so that the lower face 12which is the mounting face of the package 1 is a plane in parallel withthe XY plane. The first direction in which the end 311 a of the firstelectrode 31 opposes the end 321 a of the second electrode 32 is theX-axis direction, and the second direction which is perpendicular to thefirst direction is the Y-axis direction. The direction perpendicular tothe mounting face, the height direction of the package 1, is the Z-axisdirection.

The support member 2 includes walls 22 and collars 23. The supportmember 2 can be formed by molding a resin material.

The walls 22 secure the first electrode 31 and the second electrode 32,as well as structuring the lateral walls that surround the lateral facesof the first recess 11. The walls 22 have a first outer lateral face 21a, a second outer lateral face 21 b which is adjacent to the first outerlateral face 21 a, a third outer lateral face 21 c which is adjacent tothe second outer lateral face 21 b and opposes the first outer lateralface 21 a, and a fourth outer lateral face 21 d which is adjacent to thefirst outer lateral face 21 a and the third outer lateral face 21 c.

The first outer lateral face 21 a, the second outer lateral face 21 b,the third outer lateral face 21 c, and the fourth outer lateral face 21d are perpendicular to the lower face 21 e up to the heights of theupper faces of the first electrode 31 and the second electrode 32, andare inwardly oblique beyond the heights towards the top in the +Zdirection.

The first outer lateral face 21 a, the second outer lateral face 21 b,the third outer lateral face 21 c, and the fourth outer lateral face 21d may be entirely perpendicular or oblique.

The inner lateral faces 21 f of the walls 22 which structure the lateralfaces of the first recess 11 are outwardly oblique from the bottom face11 a towards the open end. The inner lateral faces 21 f may beperpendicular faces, but are preferably outwardly oblique faces. Makingthem oblique allows for the light emitted by the light emitting elementmounted in the first recess 11 and propagating transversely to bereflected towards the open end, thereby increasing the light extractionefficiency.

The collars 23 are provided so as to project outwardly from the firstouter lateral face 21 a and the third outer lateral face 21 c of thewalls 22 in a plan view. The collars 23 are provided on both sides ofeach of the outer lead portions 312 and 322 in a plan view with the samethickness as the outer lead portions 312 and 322. The walls 22 and thecollars 23 are integrally formed using the same material. Because theyare integrally molded, the bonding strength between the walls 22 and thecollars 23 can be increased.

The collars 23 can alternatively be provide on both sides or one side ofone of the outer lead portions 312 and 322, or may be omitted.

In the package 1, the first electrode 31 projects from the first outerlateral face 21 a and the second electrode 32 projects from the thirdouter lateral face 21 c, but neither the first electrode 31 nor thesecond electrode 32 projects from the second outer lateral face 21 b orthe fourth outer lateral face 21 d. In other words, the entire secondouter lateral face 21 b and the entire fourth outer lateral face 21 dare formed of the same material, i.e., a resin, as that of the walls 22.Thus, the solder wettability is low when the package 1 is soldered to anexternal mounting substrate, for example, thereby reducing solderwetting onto the second outer lateral face 21 b and the fourth outerlateral face 21 d.

In the package 1, the second outer lateral face 21 b and the fourthouter lateral face 21 d are each provided with a second recess 24substantially in the center in the first direction, the X-axisdirection, in which the tip 311 a of the first electrode 31 and the tip321 a of the second electrode 32 oppose one another. The second recesses24 are created by cutting off or indenting a portion of the lower face21 e of the support member 2 at the lower end of the second outerlateral face 21 b and the fourth outer lateral face 21 d.

The size of the second recesses 24 is not limited, but the width in theX-axis direction is preferably in a range between 500 μm and 700 μm,particularly preferably in a range between 600 μm and 650 μm, and thedepth in the Y-axis direction is preferably in a range between 20 μm and90 μm, particularly preferably in a range between 40 μm and 60 μm. Theheight of the second recesses 24 in the Z-axis direction is the same asthe height (i.e., thickness) of the lead frame 3.

The second recesses 24 are where the two hanger leads preformed in thelead frame used for producing the package 1 once were. In the case wherethe lead frame 3 shown in FIGS. 5A and 5B, for example, is used inproducing the package 1, the second recesses 24 would have the sameshapes as the tips 351 of the hanger leads 35. The details will bedescribed later, but the hanger leads 35 are formed so that the upperouter edges are rounded, and the lower outer edges are not rounded.

The second recesses 24 each has a columnar outer shape having atrapezoid bottom face in a plan view, which is tapered towards thecentral portion of the support member 2.

The second recesses 24 are each an area surrounded by the upper face 24a (the lower face of the support member 2), the lateral face 24 c, thelower face 24 b which is a virtual extension of the lower face 21 e ofthe support member 2, and a virtual extension of the second outerlateral face 21 b (or the fourth outer lateral face 21 d) of the supportmember 2. The inner edges at the upper end of the second recesses 24,which are the upper face corners 24 d connecting the upper face 24 a andthe lateral faces 24 c, are rounded.

Examples of the resin materials (first resin) used for the supportmember 2 include thermoplastic resins and thermosetting resins.

In the case of thermoplastic resins, for example, polyphthalamideresins, liquid crystal polymers, polybutylene terephthalate (PBT),unsaturated polyester, or the like, can be used.

In the case of a thermosetting resin, for example, epoxy resins,modified epoxy resins, silicone resins, modified silicone resins, or thelike, can be used.

The support member 2 may contain particles of a light reflectingsubstance so that light is efficiently reflected at the inner lateralfaces 21 f of the walls 22 of the support member 2. The light reflectingsubstance is a material providing high light reflectance at the externalfaces, including white fillers, such as titanium oxide, glass fillers,silica, alumina, zinc oxide, or the like, when contained in a resinmaterial. The inner lateral faces 21 f preferably have reflectance of atleast 70%, more preferably at least 80%, relative to visible light.Particularly, they preferably have reflectance of at least 70%, morepreferably at least 80%, in the wavelength range of the light emittedfrom the light emitting element.

The content of the light reflecting substance in the resin material canbe, without limitation, in a range between 5 percent by mass and 50percent by mass, preferably in a range between 10 percent by mass and 30percent by mass.

The first electrode 31, one of the pair of electrodes, is structuredwith an inner lead 311 disposed in the area where the walls 22 aredisposed or on the inner side of the walls 22, and an outer lead 312disposed on the outer side of the walls 22 in a plan view.

The second electrode 32, the other of the pair of electrodes, has thesame shape as, and is substantially symmetrical to the first electrode31 across the center line C in the first direction, X-axis direction, ina plan view. The first electrode 31 and the second electrode 32 areformed in substantially the same thickness in whole.

The inner lead 311 of the first electrode 31, in a plan view, isdisposed in the area that is on the inner side of the outer edges of thewalls 22, and is used to electrically connect the light emitting elementby die bonding or/and solder or wire. The inner lead 311, in a planview, is substantially oblong, but the width on the outer side in X-axisdirection is smaller than the width on the inner side, towards thecenter.

The outer lead 312 of the first electrode 31 is disposed so as toproject from the first outer lateral face 21 a of the support member,and in the same width as the outer side of the inner lead 311 in X-axisdirection. Collars 23 having the same thickness are provided at bothends of the outer lead 312 in the second direction, Y-axis direction,and a third recess 313 is created at the end in the X-axis direction.The third recess 313 has no collar 23.

In order to increase the light reflectance or/and the adhesion to aconductive bonding material such as solder, the upper face 31 a and thelower face 31 b of the first electrode 31 are plated with a single layeror multilayer of Ag, Au, or Ni. The end face 312 a of the outer lead 312is not plated, but the end face 313 a of the third recess 313 is plated.Thus, when bonding the third recess 313 to an external mountingsubstrate using solder, for example, the solder creeps up the lateralface 313 a to form a solder fillet, improving the bonding strength.Moreover, whether the solder bonding is good or not can be checked byobserving the presence or absence of the solder fillet.

The metal used for plating can vary depending on the purpose of plating,in other words, depending on the area to be plated. For example, Ag maybe used for the upper face 31 a to primarily increase light reflectance,and Au may be used for the lower face 31 b and the lateral face 313 a toprimarily enhance the bonding with solder.

Since the inner lead 321, the outer lead 322, and the third recess 323of the second electrode 32 are similar to the inner lead 311, the outerlead 312, and the third recess 313 of the first electrode 31, theexplanation will be omitted.

As for the third recesses 313 and 323, it suffices to dispose only oneof the two, or it is also fine to dispose neither. The third recesses313 and 323 can be shaped in any given way. It may also be fine not toprovide the collars 23 and the outer leads 312, 322 projecting from thewalls 22 described above.

The shape of the third recesses 313 and 323 is not particularly limited,but is preferably a semispherical, semielliptical, or semi-oval shape ina plan view. In the case of a semielliptical or semi-oval shape, theratio of the short diameter to the long diameter is preferably in arange between 10:11 and 10:80, more preferably in a range between 10:15and 10:60. For example, the long diameter of a semielliptical orsemi-oval shape can be in a range of 160 and 320 μm relative to theshort diameter of 50 μm.

The outer edges on the lower face side of the first electrode 31, i.e.,the lower face corners 31 e connecting the lower face 31 b and thelateral faces 31 c, in a plan view, are rounded. The outer edges on theupper face side of the first electrode 31, i.e., the upper face corners31 d connecting the upper face 31 a and the lateral faces 31 c are notrounded. The outline of the first electrode 31 is formed bypress-punching in the production method described later, and the burredface of the steel sheet after press-punching is used as the upper face31 a, and the dull face as the lower face 31 b.

Here, the lower face corners 31 e “being rounded” means that the radiusof curvature at these corners is larger as compared to the upper facecorners 31 d which are not rounded. This is also true for the secondelectrode 32 and the hanger lead 35.

Since the shapes of the upper face edges and the lower face edges of thesecond electrode 32 are similar to those of the first electrode 31, theexplanation will be omitted.

Method for Producing Package

The method for producing the package 1 will be explained next withreference to FIGS. 3-8.

FIG. 3 is a flowchart showing the steps in the method for producing thepackage according to Embodiment 1. FIG. 4A is a plan view showing thelead frame structure formed in a first outline forming step in themethod for producing the package according to Embodiment 1. FIG. 4B is asectional view along line IVB-IVB indicated in FIG. 4A showing the firstoutline forming step in the method for producing the package accordingto Embodiment 1. FIG. 4C is a sectional view along line IVC-IVCindicated in FIG. 4A showing the first outline forming step in themethod for producing the package according to Embodiment 1. FIG. 5A is aplan view showing the lead frame structure formed in a second outlineforming step in the method for producing the package according toEmbodiment 1. FIG. 5B is a sectional view along line VB-VB indicated inFIG. 5A showing the second outline forming step in the method forproducing the package according to Embodiment 1. FIG. 6A is a sectionalview showing a lead frame positioning step in the support member formingstep of the method for producing the package according to Embodiment 1.FIG. 6B is a plan view showing the lead frame positioning step in thesupport member forming step of the method for producing the packageaccording to Embodiment 1. FIG. 7A is a sectional view along lineVIIA-VIIA indicated in FIG. 6B showing a first resin injecting step inthe support member forming step of the method for producing the packageaccording to Embodiment 1. FIG. 7B is a sectional view along lineVIIB-VIIB indicated in FIG. 6B showing a first resin injecting step inthe support member forming step of the method for producing the packageaccording to Embodiment 1. FIG. 7C is a sectional view along lineVIIC-VIIC indicated in FIG. 6B showing a first resin injecting step inthe support member forming step of the method for producing the packageaccording to Embodiment 1. FIG. 8 is a plan view showing an electrodeseparating step of the method for producing the package according toEmbodiment 1.

FIG. 4A is a plan view, and the areas where through holes are created bypress-punching in the first outline forming step are hatched. Moreover,in FIGS. 4B and 4C, the areas where through holes are created in thelead frame by press-punching in the first outline forming step areindicated by the same hatching as those shown in FIG. 4A.

FIG. 5A is also a plan view, and the areas where through holes arecreated by press-punching in the second outline forming step arehatched. Moreover, in FIG. 5B, the areas where through holes are createdin the lead frame by press-punching in the second outline forming stepare indicated by the same hatching as those shown in FIG. 5A.

FIG. 7C includes an enlarged view of the portion encircled by the dottedline partially showing an outer edge of the first electrode 31 and thetip 351 of the hanger lead 35.

The method for producing the package according to this embodimentincludes a lead frame preparation step S110, a support member formingstep S120, and an electrode separating step S130.

The lead frame preparation step S110 is a step of preparing a lead frame3 which includes a first electrode 31, a second electrode 32, and hangerleads 35 by processing flat sheet metal. The lead frame preparation stepS110 includes a first outline forming step S111, a second outlineforming step S112, and a plating step S113.

The first outline forming step S111 is a step of forming the outlines ofthe first electrode 31, the second electrode 32, and other parts,excluding the outlines of the hanger leads 35 by press-punching orblanking flat sheet metal. For this purpose, the die 400 and the punch410 used in press-punching have the blades shaped to match the throughholes 361 for forming the outlines of the first electrode 31 and thesecond electrode 32, and the through holes 37 for forming the thirdrecesses 313 and 323 provided at the end of the outer leads 312 and 322.The through holes 361 are formed so as to secure a certain width ofsheet metal from the outline of the hanger leads 35 to allow for goodpress-punching to be performed in the second outline forming step S112.The through holes 37 are formed so as to straddle the outline of theplanned formation area 20 for the support member 2.

In this step, press-punching is performed from the lower face 3 b sideby using a punch 410 so that the lower face 3 b of the lead frame 3becomes a dull face. This forms rounded outer edges on the lower faceside of the first electrode 31 and the second electrode 32.

In this embodiment, the die 400 is situated on the upper side whilesituating the punch 410 on the lower side, but the die 400 may besituated on the lower side and the punch 410 on the upper side, or thedie 400 and the punch 410 may be arranged sideways. Any configurationwill be fine, so long as press-punching is performed using the punch 410from the side that will be the lower face 3 b of the lead frame 3.

For the sheet metal which is the raw material for the lead frame 3, anythat is for use in lead frames for semiconductor element packages can beused. The thickness of the sheet metal can be appropriately selected inaccordance with the package shape and size, and for example, a metalsheet of 100 to 500 μm in thickness is used, more preferably 120 to 300μm in thickness. For the material for the metal sheet, a Cu alloy, forexample, is used.

The second outline forming step S112 is a step of forming the outlinesof the hanger leads 35 by press-punching the lead frame 3 in which theoutlines of the first electrode 31 and the second electrode 32 have beenformed by the first outline forming step S111. For this purpose, the die420 and the punch 430 for use in press-punching have the blades shapedto match the through holes 362 for forming the outlines of the hangerleads 35.

The through holes 362 are communicated and integrated with the throughholes 361 to form the through holes 36.

Press-punching (blanking or cutting) using the punch 430 is performedfrom upper face 3 a side so that the upper face 3 a becomes the dullface at the edges of the through holes 362. This forms rounded outeredges on the upper face side of the hanger leads 35.

Similar to the first outline forming step S111 described earlier, eitherthe die 420 or the punch 430 may be situated on the lower side, or theymay be configured sideways.

Either of the first outline forming step S111 and the second outlineforming step S112 may precede the other. Moreover, the first outlineforming step S111 and the second outline forming step S112 may beperformed simultaneously with combination dies structured topress-punching from both sides of the upper face 3 a and the lower face3 b of the lead frame 3 using punches 410 and 430, respectively.

It suffices for the lead frame 3 to have a dull lower face 3 b at theouter edges of the first electrode 31 and the second electrode 32 thatremain in the package 1 when completed, and a dull upper face 3 a in theareas where the hanger leads 35 bite into the support member 2 and theadjacent areas. As for the remaining area, the lower face 3 b can be aburred face or a dull face.

The lead frame 3 formed by this step is such that, in a plan view, theportions formed in the inner side of the planned formation area 20 forthe support member 2 become the first electrode 31 and the secondelectrode 32. The end 311 a of the first electrode 31 and the end 321 aof the second electrode 32 oppose one another spaced apart at the centerin the first direction, x-axis direction. The first electrode 31, in aplan view, is connected to the outer frame 30 via the connecting portion33 which outwardly extends from one of the pair of short sides of theplanned formation area 20 for the support member 2. The second electrode32 is connected to the outer frame 30 via the connecting portion 34which outwardly extends from the other of the pair of short sides of theplanned formation area 20 for the support member 2.

The tips 351 of the two hanger leads 35 are opposing one another in thesecond direction, Y-axis direction, at the center in the firstdirection. The hanger leads 35, moreover, are positioned so that thetips 351 are on the inside of the pair of long sides of the plannedformation area 20 for the support member 2 which is rectangular in aplan view, each outwardly extending from the long sides and connected tothe outer frame 30.

The tips 351 are trapezoids in a plan view. The plan view shape of thetips 351 may be oblong in shape, but it is preferable to be taperedtowards the inside of the planned formation area 20 for the supportmember 2. The size of the trapezoid shape for the tips 351 is notparticularly limited, and for example, the upper base can be set to400-500 μm, the lower base 500-700 μm, and the height 50-150 μm. Theplan view shape of the tips 351 may alternatively be semispherical,triangular, or the like. The two tips 351 are positioned so as to biteinto a pair of outer lateral faces of the support member 2 in order tosupport the package 1 on the lead frame 3, but by providing a taperedshape, an application of an appropriate external force can detach thetips 351 of the hanger leads 35 from the support member 2.

The case of producing a single package 1 will be explained, but thepackages 1 can be produced in a one- or two-dimensional array. In thatcase, it suffices to form, for example, an aggregate of lead framescontinuously arranging the lead frame 3 shown in FIG. 4A in a one- ortwo-dimensional array.

The plating step S113 is a step of applying Ag electroplating or thelike on the surface of the lead frame 3 in order to improve the lightreflectance or/and solder bonding. In this step, the upper face and thelower face of the lead frame 3, and the lateral faces, including theinner lateral faces of the through holes 36 and 37, are plated.

In lieu of the plating step S113, using a sheet metal whose surface hasbeen plated can be used as the raw material for the lead frame 3 toperform the first outline forming step S111 and the second outlineforming step S112.

The support member forming step S120 is a step of molding the supportmember 2 using a first resin to support the first electrode 31 and thesecond electrode 32 of the lead frame 3. The support member forming stepS120 includes a lead frame positioning step S121, a first resininjecting step S122, and a first resin solidifying or curing step S123.

For the resin material, the first resin, for forming the support member2, the aforementioned thermoplastic resins and thermosetting resins canbe used. The support member 2 can be formed by injection molding if athermoplastic resin, such as a polyphthalamide resin, is used for theresin material, and by transfer molding if a thermosetting resin, suchas an epoxy resin, is used.

The lead frame positioning step S121 is a step to interpose the leadframe 3 between the upper die 500 and the lower die 510 of the moldingdie. The upper die 500 has a hollow 501 corresponding to the shape ofthe walls 22 of the support member 2, and the flat portion adjacent tothe hollow 501. The hollow 501 is a ring shape in a plan view.

The lead frame 3 is aligned so that the wall formation area 20 a of theplanned formation area 20 for the support member 2 coincides with theoutline of the hollow 501 of the upper die 500, and the through holes 37are on the outer side of the hollow 501 in a plan view.

The upper die 500 is provided with a gate 502 for injecting the firstresin which is located in the area where the through holes 36 of thelead frame 3 are provided, and on the outside of the planned formationarea 20 for the support member 2 in a plan view when aligned with thelead frame 3.

The lower die 510 has a flat upper face. The lower face 3 b of the leadframe 3 is flat in its entirety. Accordingly, interposing the lead frame3 between the lower die 510 and the upper die 500 makes the lower faces31 b and 32 b of the first electrode 31 and the second electrode 32coplanar with the lower faces 35 b of the hanger leads 35. Furthermore,since the upper face of the lower die 510 is flat, the lower face 21 ewhich is the lower end face of the support member 2 also becomescoplanar with the lower faces 31 b, 32 b, and 35 b.

The first electrode 31, the second electrode 32, and the hanger leads 35may have non-flat portions by bending in some region. In this case, itsuffices for the lower end portions of the lower face 31 b, 32 b, and 35b to be formed coplanar with the lower face 21 e which is the lower endface of the support member 2.

The first resin injection step S122 is a step of injecting a first resininside the molding die from the gate 502 while the lead frame 3 isinterposed between the upper die 500 and the lower die 510.

Here, the gate 502, through holes 36, and hollow 501 are communicatedwith one another, but the through holes 37 are not communicated withthese spaces. Accordingly, the first resin is injected into the throughholes 36 and the hollow 501, but not into the through holes 37.

The first resin penetrates between the upper face of the lower die 510and the rounded lower face corners 31 e and 32 e of the first electrode31 and the second electrode 32, however, does not penetrate between theupper face of the lower die 510 and the lower face corners 35 e of thehanger leads 35 which are not rounded. Thus, no burrs will be formed atthe lower ends of the second recesses 24 formed after removing thehanger leads 35 in the separation step S240 described later.

The first resin solidifying or curing step S123 is a step of solidifyingor curing the resin injected into the molding die.

Here, in the case of using a thermoplastic resin as the resin material,solidifying the heated molten thermoplastic resin by cooling is referredto as “solidifying.” In the case of using a thermosetting resin as theresin material, solidifying the liquid thermosetting resin by heating isreferred to as “curing.”

By solidifying or curing the first resin filling the hollow 501 of theupper die 500 and the through holes 36 of the lead frame 3, the walls 22are formed in the hollow 501, and the collars 23 are formed in thethrough holes 36. The collars 23 are formed in the through holes 36 sothat the molding made of the first resin continuously extends to theareas outside the planned formation area 20 for the support member 2 ina plan view. The first electrode 31 and the second electrode 32 of thelead frame 3 are firmly supported by the support member 2 which has thewalls 22 and the collars 23. The support member 2, which isparallelepiped, is placed so that the tips 351 of the two hanger leads35 bite into the pair of opposing faces, the second outer lateral face21 b and the fourth outer lateral face 21 d.

Accordingly, the package 1, which is composed of the support member 2formed in this step, the first electrode 31, and the second electrode32, is connected to the outer frame 30 of the lead frame 3 by theconnecting portions 33 and 34, and hanger leads 35.

The first resin remaining in the gate 502 is solidified to form a gatemark 25.

The electrode separation step S130 is a step of separating the firstelectrode 31 and the second electrode 32 from the lead frame 3. Thisstep can be performed by forming through holes 38 by press-punching, orblanking, the connecting portions 33 and 34 which attach the firstelectrode 31 and the second electrode 32 to the lead frame 3. Thepress-punching forms the through holes 38 whose border lines on thepackage 1 side coincide with the outer lines of the planned formationarea 20 for the support member 2. At this time, the connecting portions33 and 34 together with the extended portions of the first resin formedcontinuously to the collars 23 in the through holes 36 are removed.Furthermore, the gate mark 25 formed in the extended portion is alsoremoved. Accordingly, the package 1 when completed has no gate mark 25.This allows for the package 1 to be formed thin.

Since the electrode separation step S130 is a step to form the outlinesof the outer leads 312 and 322 of the first electrode 31 and the secondelectrode 32, press-punching is performed using a punch from the lowerface 3 b side of the lead frame 3 so as not to generate burrs on thelower faces 31 b and 32 b, which form the mounting face.

The formation of the through holes 38 causes a portion of each of thethrough holes 37 which have been formed to straddle the outer lines ofthe planned formation area 20 of the support member 2 to result in thethird recesses 313 and 323 of the outer leads 312 and 322 of the firstelectrode 31 and the second electrode 32.

Here, the end faces 312 a and 323 a of the outer leads 312 and 322formed by the through holes 38 are the exposed surfaces of the sheetmetal material of the lead frame 3, but since the lateral faces 313 aand 323 a of the third recesses 313 and 323 are plated, they have goodsolder wettability. For this reason, when the package 1 is solder bondedusing the lower faces 31 b and 32 b of the first electrode 31 and thesecond electrode 32 as the mounting face, the solder fillets formed onthe lateral faces 313 a and 323 a can increase the bonding strength.

As described earlier, moreover, whether solder bonding is good or notcan be determined by checking the presence or absence of the solderfillets.

The first electrode 31 and the second electrode 32 are separated fromthe lead frame 3 by this step, but the package 1 is supported by thehanger leads 35 and is connected to the lead frame 3. The package 1 canbe detached from the lead frame 3 by pushing the package 1 from thelower face side to the upper face side, or in +Z-axis direction, out ofthe lead frame 3.

In this embodiment, moreover, the first electrode 31 and the secondelectrode 32 were separated from the lead frame 3 by forming the throughholes 38 by press-punching, but the method is not limited to this. Forexample, they can be cut along the outline of the planned formation area20 for the support member 2 using a lead cutter.

In this embodiment, since the first electrode 31 and the secondelectrode 32, as well as the hanger leads 35, are arranged with goodsymmetry, bias in the stress applied to the first electrode 31 and thesecond electrode 32 can be reduced when the package 1 is separated fromthe lead frame 3. As a result, the first electrode 31 and the secondelectrode 32 are less vulnerable to deformation or separation from thesupport member 2.

Forming the upper end inner corners of the second recesses 24, whichhave appeared after detaching the tips 351 of the hanger leads 35, to berounded makes the support member 2 less vulnerable to cracking orbreaking within the second recesses 24.

Other Variations

In this embodiment, the support member 2 is oblong in shape in a planview, but may have a circular, elliptical, or any other polygonal shape.

The total number of the tips 351 of the hanger leads 35 that bite intothe second outer lateral face 21 b and the fourth outer lateral face 21d of the support member 2 may be three or more. Furthermore, in lieu of,or in addition to these, the hanger leads 35 may be disposed to biteinto the first outer lateral face 21 a or/and the third outer lateralface 21 c. The locations thereof are not limited to the central portionsof the outer lateral faces, and can alternatively be disposed at thecorner portions.

The first electrode 31 and the second electrode 32 may be configured soas not to have line symmetry in which either one is larger than theother.

In this embodiment, moreover, the lower faces 31 b and 32 b of the firstelectrode 31 and the second electrode 32 are formed flat and coplanarwith one another, but a portion can be configured higher than the lowerend face of the package 1 by performing bending or the like. In thiscase, the outer edges of the area that is configured higher than thelower end face of the package 1 do not need to be rounded. In otherwords, since this area does not come into contact with the mountingsubstrate even if burrs are formed, press-punching can be performedwhile orienting the lower face 31 b as a burred face.

Light Emitting Device Structure

Next, the structure of the light emitting device using the packageaccording to Embodiment 1 will be explained with reference to FIG. 9.FIG. 9 is a perspective view showing the structure of the light emittingdevice according to Embodiment 1.

The light emitting device 100 of Embodiment 1 includes a package 1A, alight emitting element 4 mounted in the first recess 11 of the package1A, and a sealing member (a second resin) 6 covering the light emittingelement 4. In this embodiment, the light emitting element 4 iselectrically connected to the first electrode 31 and the secondelectrode 32 using a wire 5.

The package 1A differs from the package 1 described earlier by havingwalls 22A, in lieu of the walls 22, which include a marking 26 for thepolarity of the first electrode 31 created by cutting off or indenting apeak of the substantially parallelepiped outline. The shape, size, andthe location of the marking 26 are not particularly limited, and it canalso be provided on the second electrode 32 side, for example. Moreover,the package 1 which does not have the marking 26 may be used instead ofthe package 1A.

The package 1A is otherwise constructed in a similar manner to in thecase of package 1, and thus the detailed explanation will be omitted.

The light emitting element 4 is mounted on the second electrode 32 ofthe package 1A. The light emitting element 4 used here is notparticularly limited in terms of the shape, the size, or thesemiconductor material. For the emission color of the light emittingelement 4, any wavelength can be selected in accordance with theapplication. A light emitting element made of a nitride semiconductorrepresented by In_(X)Al_(Y)Ga_(1−X−Y)N (0≤X≤1, 0≤Y≤1, X+Y≤1) having awavelength in the range from the near ultraviolet to the visible lightregion can suitably be used.

In this embodiment, the light emitting element 4 is of a face-up type inwhich both the positive and negative electrodes are arranged on the sameface, but can be of a face-down type in which the positive and negativeelectrodes are arranged on opposing faces.

The wire 5 is a conductive wire for electrically connecting theelectronic components, such as the light emitting element 4 andprotective element to the first electrode 31 and the second electrode32. Examples for the wire 5 include metals such as Au (gold), Ag(silver), Cu (copper), Pt (platinum), and Al (aluminum), as well as thealloys thereof, but it is particularly preferable to use Au which hashigh thermal conductivity. The size of the wire 5 is not particularlylimited, and any size can be appropriately selected in accordance withthe purpose and application.

The sealing member (the second resin) 6 covers the light emittingelement 4 mounted in the first recess 11 of the package 1A. The sealingmember 6 is provided to protect the light emitting element 4 fromexternal forces, dust, and moisture, as well as achieving good heatresistance, weather resistance and light resistance of the lightemitting element 4. For the sealing member 6, a transparent materialsuch as thermosetting resins, for example, silicone resins, epoxyresins, and urea resins can be used. In order to impart a certainfunction, a phosphor (a wavelength converting substance), lightreflecting substance, light diffusing substance, and other fillers maybe added to these materials.

By having the sealing member 6 contain phosphor particles, for example,the color tone adjustment of the light emitting device 100 can befacilitated. A phosphor which has a greater specific gravity than thatof the sealing member 6, absorbs and converts the light from the lightemitting element 4 can be used. The phosphor, given the greater specificgravity than that of the sealing member 6, can settle and be positionednear the surfaces of the first electrode 31, the second electrode 32 andthe light emitting element 4.

Specific examples include yellow phosphors, such as, YAG (Y₃Al₅O₁₂:Ce),silicate, and the like, and red phosphors, such as CASN (CaAlSiN₃:Eu),KSF (K₂SiF₆:Mn), and the like.

As for the fillers that the sealing member 6 can contain, for example,particles of SiO₂, TiO₂, Al₂O₃, ZrO₂, MgO, and the like, can suitably beused. For the purpose of eliminating the light of unwanted wavelengths,an organic or inorganic pigment or dye may also be used.

Method for Producing Light Emitting Device

Next, the method for producing the light emitting device using thepackage of Embodiment 1 will be explained with reference to FIGS. 9 and10. FIG. 10 is a flowchart showing the steps in the method for producingthe light emitting device of Embodiment 1.

The method for producing the light emitting device according to thisembodiment includes a package preparation step S210, a light emittingelement mounting step S220, a sealing step S230, and a separation stepS240.

The package preparation step S210 includes a lead frame preparation stepS110, a support member forming step S120, and an electrode separationstep S130. The package preparation step S210 performs the productionmethod for the package described earlier, and thus the detailedexplanation will be omitted.

The light emitting element mounting step S220 is a step for mounting alight emitting element 4 in the first recess 11 of the package 1A.

In this embodiment, the light emitting element 4 is of a single-sidedelectrode structure in which the n-side electrode and the p-sideelectrode are formed on the upper face side, and is mounted face up.Accordingly, the lower face of the light emitting element 4 is bonded tothe upper face of the second electrode 32 using an insulating diebonding member. The n-side electrode and the p-side electrode of thelight emitting element 4 are connected to the upper faces of the firstelectrode 31 and the second electrode 32 of the corresponding polarityusing wires 5.

In this embodiment, the light emitting element 4 is of a face-up type inwhich the positive and negative electrodes are arranged on the sameface, but may be of a face-down mounting or flip chip type in which thepositive and negative electrodes are arranged on different faces.

The sealing step S230 is a step for covering the light emitting element4, the protective element, and the wires 5 installed in the first recess11 with a sealing member 6.

This step is performed by applying the sealing member 6 inside the firstrecess 11. As a method for applying the sealing member 6, potting cansuitably be used. The sealing member 6 can be formed by filling thefirst recess 11 with a liquid resin material, and solidifying or curingit. Potting is preferable because the air remaining in the first recess11 can be effectively evacuated. For the method for filling the firstrecess 11 with the sealing member 6, various printing methods and resinmolding methods can also be used.

The separation step S240 is a step of separating the light emittingdevice 100 attached to the outer frame 30 of the lead frame 3 into anindividual piece by detaching it from the hanger leads 35.

As described earlier, by pushing the package 1 from the lower face sideto the upper face side, i.e., in the +Z direction, out of the lead frame3, the package 1 can be separated from the lead frame 3.

The light emitting device 100 can be produced by performing each of thesteps described above.

The method may be adapted to perform the light emitting element mountingstep S220 and the sealing step S230 between the support member formingstep S120 and the electrode separation step S130 of the packagepreparation step S210. In other words, the light emitting device 100 canbe separated into an individual piece after mounting and sealing thelight emitting element 4 while the package 1A remains unseparated bybeing firmly attached to the lead frame 3 using the connecting portions33 and 34 in addition to the hanger leads 35.

Alternatively, the light emitting element mounting step S220 and thesealing step S230 may be performed after the electrode separation stepS130 and the separation step S240. In other words, the light emittingelement 4 can be mounted and sealed after package 1A is separated intoan individual piece.

In addition, the order of the steps can be changed so as to conform tothe conditions described below.

As for the electrode separation step S130, it is fine as long as it isperformed before the separation step S240. Accordingly, the electrodeseparation step S130 may be performed after the light emitting elementmounting step S220 and the sealing step S230, or between the lightemitting element mounting step S220 and the sealing step S230.

As for the light emitting element mounting step S220, it is fine as longas it is performed after the support member forming step S120 of thepackage preparation step S210, but before the sealing step S230.Accordingly, the light emitting element mounting step S220 may beperformed after the electrode separation step S130. Moreover, the lightemitting element mounting step S220 may be performed after theseparation step S240.

As for the sealing step S230, it is fine as long as it is performedafter the light emitting element mounting step S220. Accordingly, thesealing step S230 may be performed after the electrode separation stepS130 and the separation step S240.

EXAMPLES

The light emitting device shown in FIG. 9 was produced using theaforementioned production method under the conditions described below.

A Cu sheet metal with Ag plating on the surface was used as the rawmaterial for the lead frame.

A polyphthalamide resin was used as the raw material for the supportmember which was formed by injection molding.

Moreover, titanium oxide particles were added to the support memberresin material to bring the reflectance of the inner surfaces of thefirst recess of the support member to at least 70%. The reflectance isbased on the value at the emission peak wavelength of the light emittingelement as a reference.

The package outline is a box shape of about 2.2 mm in length, about 1.4mm in width, and about 0.7 mm in height. The wall thickness is in arange of about 0.12 mm and 0.30 mm. The thickness of the lead frame andthe thickness of the collars is about 0.2 mm. The hanger leads aresubstantially trapezoids in a plan view with an upper base of about 0.4mm, a lower base connected to the outer frame of about 0.66 mm, and aheight from the upper base to the lower base of about 0.05 mm. The thirdrecess is substantially semi-oval shaped in a plan view with a longdiameter of about 0.30 mm and a short diameter of about 0.05 mm.

For the light emitting element, a nitride-based blue light emittingdiode having an emission peak in the vicinity of 460 nm was used.

A silicone resin is used for the sealing member.

After installing the light emitting element in the package, the firstelectrode and the second electrode were cut from the outer frame bypress punching. At this time, the package was supported by the hangerleads. Subsequently, the light emitting device was separated by applyinga pressing force from the lower face side of the package to be detachedfrom the hanger leads.

The separated light emitting device (package) had a flat lower facewhich is the mounting face free of resin burrs.

The light emitting device according to certain embodiments of thepresent disclosure can be utilized in lighting devices, automotive lightemitting devices, and the like.

Obviously, numerous modifications and variations of the presentinvention are possible in light of the above teachings. It is thereforeto be understood that within the scope of the appended claims, theinvention may be practiced otherwise than as specifically describedherein.

What is claimed is:
 1. A method for producing a lead frame, the methodcomprising press-punching a metal sheet such that a direction ofpunching perimeters of electrodes and a direction of punching perimetersof hanger leads are opposite one another, the lead frame includes theelectrodes, the hanger leads disposed spaced apart from the electrodes,and an outer frame attached to the electrodes and the hanger leads, thelead frame partially defining a box-shaped package, which has a firstrecess for mounting a light emitting element, as combined with a supportmember made of a resin for supporting the electrodes, the first recesshaving an opening defining by lateral walls formed by the support memberand a bottom face at least partially formed by the electrodes.
 2. Themethod for producing the lead frame according to claim 1, wherein thedirection of punching the perimeters of the hanger leads is a directionfrom an upper face of the hanger leads to a lower face of the hangerleads while the package is formed.
 3. A method for producing a packagecomprising: forming the lead frame by the method according to claim 1;interposing the lead frame between an upper die and a lower die of amolding die, which are configured to move in an up-down motion and has acavity for forming the lateral walls; injecting a first resin into themolding die interposing the lead frame; and curing or solidifying thefirst resin injected in the molding die, wherein during the interposingof the lead frame, burred faces of the electrodes face the cavity, edgesof the electrodes are placed in an area where the cavity is disposed ina plan view, and tips of the hanger leads are placed in the area wherethe cavity is disposed in the plan view.
 4. A method for producing alight emitting device comprising: forming the package by the methodaccording to claim 3; and mounting the light emitting element in thefirst recess of the package.
 5. The method for producing the lightemitting device according to claim 4, further comprising separating thedevice into an individual piece by pushing out the package from a lowerface side to an upper face side of the package; and cutting theelectrodes from the outer frame after the separating of the device. 6.The method for producing the light emitting device according to claim 4,further comprising sealing the light emitting element by applying asecond resin inside the first recess after the mounting of the lightemitting element.